Wire Ropes Technical Information

08/2013
PFEIFER
SEIL- UND HEBETECHNIK
GMBH
Wire Ropes
Technical Information
DR.-KARL-LENZ-STRASSE 66
D-87700 MEMMINGEN
TELEPHONE +49 (0) 83 31-937-267
TELEFAX
+49 (0) 83 31-937-341
E-MAIL
wireropes@pfeifer.de
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Giving you a peace of mind!
Proficiency and
expert knowledge
PFEIFER is your specialist for the
application-oriented rope selection
and the delivery of customized wire
ropes. Cutting to length, prestressing,
splicing, endless laying, swaging
and hot metal socketing – this is our
business.
PFEIFER has been dealing with ropes
for generations. Leading crane and
elevator manufacturers, the port,
construction and automobile industry
as well as rope users from many
different industries are our customers.
They all trust in PFEIFER’s worldwide
renown efficient service.
Highest quality level
Wire ropes have a central function
wherever they are applied: lifting,
transporting, pulling, staying or
handling. All this involves a high
degree of responsibility; we are well
aware of this fact. The highly qualified
competent staff, the latest production
equipment and strict quality control
measures are a guarantee for the
quality standard of PFEIFER products.
A good feeling
Throughout manufacturing, with us,
you are on the safe side. We hold all
necessary licences and qualifications.
Additional proof of our high quality
standard is the certification for the
quality assurance system according
to DIN EN ISO 9001.
Efficient production,
Exact testing
Our manufacturing and test equipment
conforms to the latest requirements.
In the “coiling alley” with a 4000 t
wire rope storage capacity ropes are
cut to length to close tolerances in all
required lengths and diameters.
We provide large swaging presses
with a pressing force of 3000 t. Ropes
with a diameter up to 80 mm can be
fitted with various types of end terminations.
Two socketing towers with a capacity of 10 socketing boxes allow for
connection of sockets and rope.
In the 240 m pre-stressing tunnel
wire ropes up to 160 mm dia. can
be dynamically prestressed to exact
length. Our hydraulic prestressing
machine has a capacity rating of
6000 kN, therefore elongation-, tensile
and pull tests of ropes in high
precision class 1 are possible.
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Wire Ropes – Technical Information 08/2013
The PFEIFER group
Rope application technology
Only a rope manufactured to appropriate specifications will be able to
fulfil a given task. As a specialist in the
use of steel wire ropes, we can supply
the right rope for your job. Wire rope
manufacturing takes place at our
group company PFEIFER DRAKO
Drahtseilerei Gustav Kocks GmbH &
Co. in Mülheim, Germany.
PFEIFER is one of the leading European companies for rope, anchoring and
lifting systems. The group consists of many companies both in Germany and
abroad. PFEIFER headquarters are located in Memmingen, Germany.
Business fields
The business fields of the PFEIFER group are:
Cable structures
Mining and industry ropes
Architects can use cable structures
to transform space into vast areas of
lightness and transparency. Impressive examples of the aesthetics and
elegance of PFEIFER cable structures
can be found all over the world.
PFEIFER DRAKO in Mülheim, Germany
located in the heart of the german
coal mining area has been producing
ropes of high quality for the past
150 years. Other parts of the product
range include special steel wire ropes
for steel mills, different industrial
applications and deep sea research.
Lifting technology
Elevator products
Safely lifting heavy loads – our
development engineers have acquired
a great deal of expertise in this field.
We are your global partner when it
comes to the technological and safety
challenges involved in the integrated
lifting and moving of heavy loads.
PFEIFER DRAKO elevator ropes are
used in skyscrapers worldwide.
With the surge of highrise buildings
and highspeed elevators demands
for increased performance are met
through continuous development.
Attachment and lashing equipment
Inspection service,
technical seminars
With our experienced staff and
our extensive product program we
meet our customers’ permanently
changing needs
We completely service all your lifting
devices in your factory. We teach –
we inspect – we maintain – we repair.
Connecting and lifting systems
We are the market leaders in the fields
of lifting anchors, fixing systems and
infrastructure technology. We have
developed products of the highest
standards and believe we can offer
the most comprehensive and competitive systems for the construction
industry today.
Protection systems
against natural hazards
PFEIFER ISOFER, Switzerland is
a pioneer in the development,
manufacturing and installation
of protection systems against
natural hazards or rock and slope
stabilization.
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Wire Ropes – Technical Information 08/2013
Table of content
Technical aspects about wire rope
• Rope cores (C)
• Strand constructions
• The strand – direction of lay
• The stranded rope – direction and type of lay
• Rope types
• Surface treatment of wires / rope lubrication
• Explanation of important terms
5–8
Rope selection
• Rotation resistant ropes
• Non-rotation resistant ropes
9 – 10
• Right-hand or left-hand lay rope?
• How to determine the correct rope lay direction?
Product safety
10
Rope designations
11
Steel wire rope end finishing
12
Breaking force reduction caused by rope end terminations
13
Correct handling of wire ropes
• Spooling of wire ropes
• Storage and transport of wire ropes
• Applying of pretension in the multiplayer spooling
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Wire Ropes – Technical Information 08/2013
14 – 15
Discard
16
Approved rope quality
17
Measurement devices
18
Wire rope accessories
19
Technical Aspects about Wire Rope
History
1
3
When Wilhelm Albert, an official of the
German Board of Mines, manufactured
a wire rope in 1834, it was admittedly,
not the first wire rope in the world, but
the tools he used and the level of steel
wire production enabled him to produce
ropes of acceptable length and quality.
The ensuring rapid development of wire
rope production and its machinery and
an ever increasing number of new rope
constructions revealed, how urgently
wire ropes were needed by the emerging industrial revolution. Since then the
very simple Albert rope construction
has developed – according to the
various demands – into a vast and for
the uninformed somewhat daunting
variety of rope constructions.
Common types of ropes
• Standard ropes
• Rotation resistant ropes
• Compacted ropes
• Ropes with coated core
• Fibre core (FC) (fig. 1 and 2)
The core of the rope consists of
natural (NFC) or synthetic fibre
(SFC). Fibre cores store lubricants,
support the strands and dimish
vibrations.
Wire rope consists of three basic
components
• The core
• Wires that form a strand
• Strands laid helically around
the core
Rope cores (C)
2
The inner part of a single layer rope
surrounded by the outer strands is
normally filled by a rope core. Rope
cores are separated according to the
material and design. Its main function
is to support the outer strands and,
by using a steel core, also to increase
the load bearing metallic cross
section.
• Steel core (WC) (fig. 3)
There are two typical types of
steel core
1. Wire strand core (WSC) (fig. 4)
The core of a round strand rope
4
consists of a strand.
2. Independent wire rope core
(IWRC) (fig. 5)
The core of the round strand
rope consists of a stranded
rope.
• Independent wire rope core,
plastic coated
(fig. 6, 17)
The core consists of a plastic
coated steel core.
5
6
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Wire Ropes – Technical Information 08/2013
Strand constructions
It was obvious from a very early
stage that the structure of the strand
in particular has a great influence on
the characteristics of the rope. Over
100 years ago the Seale, Warrington,
Filler wire and the cross lay (formerly
called standard) wire configuration
were already well known. Other
common strand formations, e. g.
Warrington-Seale and Warrington –
Compound are merely combinations
of these basic constructions.
8
The strand –
direction of lay
Wire and strand diameter of our wire
ropes have been optimized constantly
by using computer technology. Thus
bending properties and service life of
the running ropes could be improved
considerably. By an absolutely equal
load distribution to all wires an early
failure of any individual wire due to
overloading will be eliminated.
Standard stranding (fig. 7 a) methods
cause wire crossings between the
wire layers within the strand resulting
in high stress concentrations, where
crossings occur. Premature damage
may be the consequence. In a parallel
stranded strand (fig. 7 b) all wires are
arranged parallel in the strand structure thus a continous linear contact is
provided. The result is a reduction of
compressive stress of the wires.
Therefore many of our special ropes
for running service are made of
parallel stranded strands. Thus an
optimum in rope work and
considerably improved service life
will be achieved.
7
mines later use of the rope. There are
basically two different types of lay.
The direction of lay of the strand is
the direction of the helix of the outer
wires. There are two types, the right
hand lay (abbreviated to z, fig. 8 a)
and the left hand lay (abbreviated to
s, fig. 8 b).
The stranded rope –
direction and type of lay
The direction of lay of the rope is the
direction of the helix of the outer
strands. There are two types, the
right hand lay (abbreviated to Z,
fig. 9 a) and the left hand lay
(abbreviated to S, fig. 9 b).
When spinning stranded ropes, different methods to combine the strands
are possible. The spinning process
9 affects rope properties and detera
b
a
b
Regular or Cross lay (fig. 10)
The direction of lay of the wires in the
outer strands will be in opposite
direction to the direction of lay of the
outer strands in the rope itself.
Regular laid ropes are more pressure
and deformation resistant.
Two types of lay direction are possible. The lay direction is determined
by the outer strands:
• sZ: right hand regular lay (fig. 10 a)
• zS: left hand regular lay (fig. 10 b)
Lang lay (fig. 11)
The direction of lay to the wires in the
outer strands equals the direction of
lay of the outer strands in the rope.
Lang lay ropes provide improved
abrasion resistant properties when
used on multiple rope reeving.
Two types of lay direction are possible. The lay direction is determined
by the outer strands:
• zZ: right hand lang lay (fig. 11 a)
• sS: left hand lang lay (fig. 11 b)
Rope types
In the following parts the most
common rope types will be explained.
Please also read “Wire rope selection” to get additional information.
6
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Wire Ropes – Technical Information 08/2013
11
12
13
14
15
Single layer stranded ropes (fig. 12)
Single layer round strand ropes consists of several strands laid in one layer
around a fibre or steel core. They are used e.g. for cranes, excavators,
winches, construction machinery, elevators and as sling rope.
Rotation resistant ropes
Rotation resistant ropes designed to generate reduced levels of torque and
rotation when loaded (fig. 13). Rotation resistant ropes generally comprise an
assembly of at least two layers of strands laid helically around a core, the
direction of lay of the outer strands being opposite of that of the underlying
16 layer. To achieve an additional reduction of torque and rotation when loaded
special rotation resistant ropes were designed and manufactured. Typical
application for these special ropes are hoisting ropes for cranes working with
only one fall and / or high lifting heights (fig. 14). Further information in
“Wire rope selection”.
Parallel-closed stranded ropes (fig. 15)
16c
Parallel-closed stranded ropes consist of at least two layers of strands laid
helically in one closing operation around a core. The diminished gaps
between the strands result in an enlarged metallic cross section and thus in
higher breaking load values. They are used e.g. for cranes, excavators,
16d construction machinery.
Low-stress ropes
If all internal stresses in the wires resulting from the manufacturing process
have been completely or nearly eliminated the rope will be low-stressed.
If seizing is removed strands remain in position. Wire breakages occuring
during rope work do not protrude from the rope structure.
High performance compacted ropes
Generally the compacted ropes may be divided into:
16e
16f
• Compacted strand stranded rope (fig. 16 e)
Rope in which the strands, prior to closing of the rope, are subject to a
compacting process such as drawing, rollingor swaging. Fig. 16 a, c shows
the standard, fig. 16 b, d the compacted strand.
• Compacted (swaged) stranded rope (fig. 16 f)
Rope which is subjected to a compacting (usually swaging) process after
closing the rope, thus reducing its diameter.
The advantages of compacted ropes are: higher breaking load, better
flexibility, smooth surface and a higher resistance to abrasion.
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Wire Ropes – Technical Information 08/2013
Ropes with plastic coated steel core (cushioned core rope) (fig. 17)
The interior structure of some of our special ropes is plastic coated.
This structure is characterised by a number of improvements
• reduced friction between rope core and outer strands
• high bending cycle strength
• high structural strength
• excellent vibration-resistant properties
• improved corrosion protection of the wire core
17
Surface treatment of wires / rope lubrication
The most common surface treatment for the wires of a rope are, either
ungalvanized or bright (U), galvanized (B) and heavy galvanized (A).
Ropes are lubricated during manufacturing process. The lubricant has two
important functions. It reduces friction between the wires in the strand and
the strands within the rope and thus supports the movements of the rope
during running over sheaves or spooling on drums. In addition it protects
from corrosion.
To maintain the positive characteristics of the base lubrication ropes have to
be relubricated regularly.
Explanation of important terms
• Nominal rope diameter
The nominal rope diameter is a size which defines a rope in combination
with other characteristics. Together with the tolerances the manufacturer or
an existing standard provides, the range for the actual rope diameter can
be determined.

• Actual diameter (fig. 18)
To measure the actual diameter it is important to do it the correct way.
Only the measurement according fig. 18 b will lead to the required result.
The measurement according to fig. 18 a is wrong.
18
• Fill factor
The fill factor is the relation of the metallic cross section of the rope to the
area of its circumscribed circle.
• Wire tensile strength grade (R)
A level of requirement of tensile strength of a wire and its corresponding
range. It is designated by the value according to the lower limit of tensile
strength and is used when specifying wire and when determining the calculated minimum aggregate breaking force a rope, expressed in N/mm².
Common tensile strength grades are 1770 N/mm2, 1960 N/mm2 and
2160 N/mm2.
• Spinning loss factor
The spinning loss factor is a pragmatical value based on the breaking load
loss of the wires during the spinning process.
• Minimum breaking load (Fmin)
The minimum breaking load of the rope is the product between nominal
aggregate breaking load and the spinning loss factor. Most of the end
terminations decrease minimum breaking load of the rope. Detail in
“Rope end terminations”.
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Wire Ropes – Technical Information 08/2013
Rope selection
Wire ropes are divided into four main groups:
Slings
… are load handling ropes.
Track rope
… are used in cable ways.
Structural cables
… are ropes being anchored at two
fixed points and do not run over
sheaves or spool on a winch,
e. g. guy and pendant ropes,
suspension ropes.
Running ropes
… are ropes running above sheaves,
drums or traction sheaves,
e.g.hoist ropes, luffing ropes,
elevator ropes, haulage ropes etc.
The most suitable rope for a given application is the one best able to withstand the conditions the rope will encounter in service. The correct choice for
rope will not only decrease the danger and hazards for personnel and
machine but will also help to prevent very expensive down time due to premature failure of ropes etc.
Avoid any risk, trust in our experience and assign this task to us. We are
always ready to assist you in finding a solution or any special rope problem
you may have, just contact us.
At the beginning of the wire rope selection the most important decision is:
“Do I need a rotation resistant or a non-rotation resistant rope?”
What is the difference between both rope types?
Rotation resistant ropes
19
Due to that, under load the core tries to twist the rope in the one direction
(fig. 19 a), the outer strands try at the same time to twist the rope in the
opposite direction (fig. 19 b). The result is, that high performance rotation
Please note! Ropes called “rotation resistant ropes” may have different levels resistant ropes almost compensate the torque over a particular load spectrum.
Because of these excellent rope properties the high performance rotation
of rotation resistance e.g. torque and rotation when loaded. To give you
restistant ropes are used with lifting heights and lifting unguided loads on a
advise to the different rope properties we have separated the rotation
single fall. Up to now these ropes were also called “non-rotation ropes”.
resistant ropes into two classes:
As explained in the part “Rope types” rotation resistant ropes designed to
generate reduced levels of torque and rotation when loaded.
1. Rotation resistant ropes
These are rope constructions, e. g. 18 x 7, 17 x 7 (fig. 13), with two layers
of strands laid helically around a core, the direction of lay of the outer
strands being opposite to that of the underlying layer.
The high performance rotation ropes can be used with or without a swivel;
if possible, the use of a swivel is preferred.
WARNING! Don’t use these ropes attached to a swivel or have
one or both ends rotate freely under load! If this is not observed
serious injury, considerable damage or death will occur!
2. High performance rotation resistant ropes (fig. 14)
We indicate the higher quality of these ropes through adding the term
“high performance”. The high performance resistant ropes have a steel
core which is an independent rope, closed in the opposite direction to the
outer strands. Today these ropes consist of 15 and more outer strands
(fig. 19).
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Wire Ropes – Technical Information 08/2013
Non-rotation resistant ropes
According to the rope properties “torque and rotation” non-resistant ropes
generate high levels of torque when loaded. That is why both rope ends must
be fixed when loaded to avoid rotation. Typical wire rope constructions are
ropes ropes with e.g. 6-, 8-, 9- or 10-outer strands. Non rotation resistant
ropes can be used, when the load is guided, in lifting systems where pairs of
the right and left hand ropes are working or when having a low lifting height
with more than one fall. Under these conditions the advantage of non-rotation
resistant ropes – compared with rotation-resitant ropes in the same application – is, that these ropes achieve a higher service life.
20
WARNING! Don’t use these ropes attached to a swivel or have
one or both ends rotate freely under load! If this is not observed
serious injury, considerable damage or death will occur!
Right-hand or left-hand lay rope?
For the installation of ropes on winches there is the basic rule:
• Right-hand lay rope for a left drum
• Left-hand lay rope for a right drum
For the correct running of the rope it is necessary that drum and reeving will
be of the same direction. If a rope runs from a right drum into a left reeving
or from a left drum into a right reeving only a test can prove whether a lefthand or a right-hand lay rope must be installed.
By using multiple layer spooling systems we recommend to follow the above
mentioned basic rule.
How to determine the correct rope lay direction?
• First step: Check how the rope runs from the drum into the reeving.
There are two possibilities:
– overwound drum (fig. 20 right)
– underwound drum (fig. 20 left)
• Second step: Put your hand on the rope on the drum
– Index finger shows in the direction of the rope running into the reeving
– Thumb shows to the rope fix point on the drum
• Third step: Decision
– If you need your left hand to fulfill the requirements of the second step,
then you need a left-hand rope (fig. 20 top figures).
– If you need your right hand to fulfill the requirements of the second step,
then you need a right-hand rope (fig. 20 lower figures).
Product safety
Our basic information in this broshure provides guidance on product safety. It is
produced for those already having knowledge of wire ropes, as well as for new
users. Please pass the basic information on to others.
Read it carefully, understand and practice these instructions, also read and understand the machinery manufacturer’s manual. If these are not observed serious
injury, death or considerable damage can occur! Protect yourself and others!
WARNING! Wire rope will fail if worn-out, shock loaded,
over-loaded, misused, damaged, improperly maintained or
abused.
Always inspect wire rope before use for:
• wear
• damages
• deformations
• corrosion
Never use wire rope which is
• damaged
• worn-out
• deformed
• improperly maintained
• not suitable
If in doubt about the wire rope, the wire rope application, the wire
rope end termination or anything else, regarding the wire rope,
please contact us or the machine maunfacturer.
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Wire Ropes – Technical Information 08/2013
Rope designations
1
Hoisting rope
2
Pendant rope
3
Luffing rope
4
Trolley rope
5
Closing rope
6
Winch rope
2
2
4
2
1
3
1
1
3
1
3
1
1
5
1
6
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Wire Ropes – Technical Information 08/2013
Steel wire rope end finishing
In most cases a steel wire rope manufactured on a master reel is not ready
to be put to work. A rope must be cut to size and the rope ends finished to
enable the rope to fulfill its task.
Not only the correct rope selection, but also a properly fitted rope end
terminations is necessary to achieve safe and satisfactory service life.
PFEIFER has a very skilled work force and our employees are educated and
trained in the specialised field of rope end finishing.
Commonly there are three ways of rope end finishing
• Cutting to size and seizing or fusing of rope ends
• Forming a loop in the rope
• Attaching a fitting to the rope
21
PFEIFER’s facilities are fitted with precision working equipment to ensure high
quality ready for use ropes.
Coiling and cutting to size: a stock arrangement for effective rope finishing
ensures short processing time (fig. 21).
Rope end seizing: seizing of rope ends avoids loosening of the rope structure. Firm seizing is absolutely necessary for rotation resistant ropes as they
are not preformed (fig. 22).
Cutting of ropes (fig. 23)
Fusing: we can taper and fuse rope ends up to a rope diameter of 34 mm.
Larger diameters, the rope ends will be welded. Such end treatment simplifies
the mounting of ropes on winches or in open wedge sockets. (fig. 24)
Swaging: aluminium ferrules or steel fittings are cold bonded to the wire rope
under extremely high pressure. Two presses, with a pressing force of 3000 t
each, enable us to swage steel wire ropes up to 80mm diameter. Swaging
reduces the minimum breaking load of ropes.
Casting: is the end finishing of a rope where there is no reduction of the
minimum breaking load. For casting the most common used materials are
zinc or resin. Two socketing towers with 5 socketing boxes each, allow
short processing time with a large number of ropes. In our plant ropes up
to 120mm diameter have already been tilted with sockets. PFEIFER is very
experienced in casting rope fittings either in our facilities or on site (fig. 26).
Pre-stressing: to achieve exact rope lengths under specified working conditions, it is necessary to pre-stress ropes with a deteremined load. A prestressing machine with a capacity rating of 6000 kN (in high precision class
1) and a pre-stressing tunnel with a length of 240 meters, enable us to do
various elongation-, tensile – and breaking tests (fig. 27).
Testing: only a test of the rope fitted with the required end terminations will
qualify the produced quality. Regular testing is necessary to guarantee a
continuos high quality (fig. 28).
22
23
24
25
26
12
27
Wire Ropes – Technical Information 08/2013
28
Breaking force reduction caused by rope end terminations
Cast open spelter socket
Flemish eye
100 %
100 %
Cast cylindrical socket
90 %
90 %
Swaged thread fitting**
Swaged eye
90 %
90 %
Swaged clamp with thread**
Swaged thimble
90 %
90 %
Closed swaged fitting**
Swaged solid thimble
90 %
90 %
Open swaged fitting**
Swaged fork end thimble
90 %
Rope clamp acc. EN 13411-5***
80 %
Spliced eye
Spliced thimble
*
80 %
80 %
Open wedge socket symmetric
80 %*
80 %
Open wedge socket asymmetric
Most rope end terminations reduce
the breaking force of the rope system
significantly. As a approximate value,
we give you the remaining value of
the minimum breaking force as a
percentage of the minimum breaking
force of the rope according to the
following table.
WARNING:
These data define the ideal case.
That means that the in rope system
used rope end terminations (especially
casting sockets, fittings and open
wedge sockets) must fit in design and
material quality regarding the used rope
type (construction, nominal strength,
compacted / uncompacted). If in doubt,
the system breaking force needs to be
determined by type testing through
tensile testing.
WARNING:
Make long splices according DIN 3089
section 2.
Please note that by splicing wire ropes
with a steel core, the metallic cross
section is to be reduced by the core!
with spliced terminations in some cases, a reduction of the tensile strength of up to 40 %
may occur. This depends on the rope construction and the rope diameter
** These terminations are only for use with full steel wire ropes (with steel core)
13
*** the use of wire clamps with compacted wire ropes is not described by the standard and
should therefore be avoided!
Wire Ropes – Technical Information 08/2013
Correct handling of wire ropes
Spooling of
wire ropes
Correct:
Lay wire rope rings
on clean ground.
Please consider the
preferred bending
direction when rewinding the rope.
Correct:
!
!
Place reel on a suitable frame or spike,
draw-off straight.
Make absolutely
sure that the rope
is not fouled.
Wrong:

Drawing-off the rope
of a ring or over
the flange of the
reel as well as
counterwise
spooling cause
“twist” for each
winding in the rope.
Loops may occur,
which may result in
bends under tension.
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Wire Ropes – Technical Information 08/2013
Storage and
transport
of wire ropes
Correct:
!
!

!

Store wire ropes dry
and cool.
Avoid ground contact,
so that humidity can
not taper the rope.
Take off air and
water tight transport packing.
Humidity causes
oxidation.
Correct:
Protect the rope of
crushes and kinks.
Wrong:
Improper transportation of wire
rope reels and
rings will cause
irreparable damage
to wires, strands or
the rope structure.
Applying of pretension
in the multiplayer
spooling
Correct:
The reel is braked
mechanical at the
flange of the reel.
Wrong:
The squeezing of
ropes with wooden
beams or similar
items cause
irreparable damage
to the rope structure.
Wire Ropes – Technical Information 08/2013
15
Discard
Looping on a wire rope
Warning: Considering security crane ropes should be
taken off operation in time, if one of the following criterias
apply:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Broken strand
Local concentration of wire breaks
Achievement of type and number of wire breaks according to the tablets
At least two wire breaks in strand valley or adjacent strands within one
lay length (approx. 6 × d)
Corkscrew deformation of more than 1/10 of the rope diameter
(g / d ≥ 0,1); d: nominal rope diameter, g: height of waviness
Corkscrew (fig. 30)
Hairpin like escape of wires (fig. 31)
Through corrosion and wear heavy loose strand
Decrease of diameter – regarding the nominal rope diameter – at uniform
decrease of:
– 7,5 % at non-rotation resistant ropes with steel core
– 5,0 % at rotation resistant ropes
Local increase of diameter of more than 5% compared with the diameter
of the rest of the rope
Heavy corrosion: The surface of the wires is strongly affected or rosty
dust comes out of the rope
Loose rope structere (fig. 32)
Constriction (fig. 33)
Kinks or flattened areas(fig. 34 + 36)
Bends or other deformations (fig 35)
Constriction due to a broken rope core
bluish discoloration, broken or fused wires due to heat effects or
electric arc
31
32
If several of the above mentioned criterias apply, they need to be considered
in their entirety. Therefore ropes need to discarded, if none of the criteria are
completely but some partially fulfilled. For example: Light Corkscrew with
some broken wires.
The above criteria are an excerpt from the ISO 4309-2010 maintenance and
care, inspection and storage. Consequently, these criteria do not replace the
instructions andrequirements for inspection and maintenance of wire ropes as
written in the standard.
If in doubt on the estimation of the cable damage, the rope must be
discarded or your rope specialist needs to be contacted:
wireropes@pfeifer.de or via phone +49 (0) 83 31-937-267.
33
Flattened wire rope caused by over-ride
34
Corkscrew deformation
16
Bend caused by a pinched
rope sling
Basket deformation
29
Wire Ropes – Technical Information 08/2013
30
Kind caused by mechanical impact
35
36
Approved rope quality
Be aware that not only the usual catalog values such as weigh/length and
minimum tensile strength determine the wire rope property PFEIFER is
analyzing all properties of the wire rope with extensive tests.
Equipped with this knowledge we can choose the optimum wire rope for
your application.
Testing machines to determine
the bending strength.
Testing facility for measuring
the resistance against lateral
pressure.
37 m high test tower to analyze
the suitability in the multilayer
spooling.
Different applications require different qualities of
corrosion protection.
Many available galvanization qualities do not meet
the requirements of individual applications.
We are one of few providers which can test the
galvanizing quality in in-house laboratories and
fulfill exceptional customer needs.
We are authorized to issue
certificates for all kind of ropes.
These certificates document that
regulatory requirements are in
place to the standards.
Tensile test facility with a capacity of
up to 6000 kN to determine the cable
system breaking forces. Tension
fatigue tests are also possible on these
systems.
Upon request we provide for
example test reports, inspection
certificates, certificates of
Germanischer Lloyd and
manufacturer declarations.
17
Wire Ropes – Technical Information 08/2013
PFEIFER-measurement devices:
by pros – for pros!
Measurement devices
Based on our long-term practical experience of rope drive inspection,
we created the following measurement devices kit. These measurement
devices are used by our rope experts for each inspection and thereby
approved for general use.
Measurement
equipment case 75
Content:
Rope caliper 75
made of galvanized steel
with attached wide jaws
Recommended for the frequent
measuring of ropes in the most
common diameters
Rope diameter
5 – 28 mm, 12 – 45 mm,
21 – 60 mm, 5 – 60 mm
Further combinations of the 5 different groove gauges kits on request
Product advantages
• Recommended for frequent
measurement of ropes with the
most common diameters up to
40 mm
• Enables quick and easy check –
wide jaws reduce measuring faults
Rope caliper 150
With attached extra wide jaws
and adapter plates for big rope
diameters
Product advantages
• Recommended for frequent measurement of ropes with diameters
up to 150 mm
• Enables quick and easy check –
wide jaws reduce measuring faults
Propeller
Stainless steel
Rope diameter
15 mm, 20 mm, 24 mm
Further sizes on request
Measurement
equipment case 150
Ring
Content:
Rope caliper 150
Groove gauges „Bolt“ with 5 kits
(see picture measurement equipment case 75)
Rope diameter
5 – 20 mm, 20 – 40 mm,
40 – 60 mm, 60 – 75 mm
Product advantages
The complete measurement
equipment case for the frequent
professional groove inspection!
Wire Ropes – Technical Information 08/2013
With attached wide jaws
Product advantages
Stellen Sie sich Ihren Messmittelkoffer nach Ihren Bedürfnissen
zusammen!
Rope diameter
5 – 60 mm
18
Rope caliper 40
Product advantages
Recommended for the frequent
check of rope drives with a specific
diameter
Stainless steel
Product advantages
Recommended for the frequent
check of rope drives with the most
common rope diameters
Rope service – starter kit
Content:
2x PFEIFER RL-S Wire rope
lubrication Spray can
1x Groove-gauge-Kit Worker
1x Pair gloves
1x Rope caliper 40
1x Yard stick
1x Steel wire brush
Product advantages
Allows quick and easy control as well
as professional care of your wire ropes
Wire rope accessories
Fittings
Fittings are manufactured using
spezial steel and are swaged directly
onto the rope end. Therefore you get
a thin rope end termination, which is
fitted by means of drilling. Threaded
fittings are to be fixed securely and
non-rotatable.
Closed swaged
fitting
Open swaged
fitting
Swaged thread
fitting
Open and closed spelter socket
Rope ends are cast in open spelter
sockets and closed spelter sockets.
Solid and fork thimbles
PFEIFER can supply solid thimbles
and forked end thimbles which are
used to join. DIN 3091 solid thimbles
are drilled to a specific diameter.
Thimble
Thimbles protect the rope eyes and
increase the life-time expectancy of
the rope considerably.
Open wedge socket
The wedge socket is a
close-end-fitting which is
commonly used on cranes.
Lubrication
Steel wire ropes need to be regularly
lubricated to maximize service life.
Shackle
Shackles are universal accessories
and have a wide range of applications. The two types of shackles
which can be supplied are ‘D’
shackles and bow shackles fitted
with screw bolts or bolt, nut and
split pin.
Pouch socket system
Fast and safe re-reeving
of wire ropes with the
PFEFER pouch socket system.
Swivel
Swivels are to be used with high
performance rotation resistant ropes
only. Swivels rotate under load and
can compensate torsion in hoisting
ropes. The ends can be supplied with
forks and with eyes.
Warning: Don’t use
non-rotation resistant or
rotation resistant ropes
with a swivel! If this is
not observed serious
injury, considerable
damage or death will
occur!
19
Wire Ropes – Technical Information 08/2013
Our locations worldwide
PFEIFER
J&P: Your reliable Partner
Toronto
St. Petersburg
Hampton
Moskau
Farsø
Crewe
London/Thame
Southampton
Rio de
Janeiro
Hamburg
Essen
Berlin
Mülheim
Wrocław
Dresden
Schifflange
Prag
Nürnberg
Changshu
Mannheim
Chalezeule
Klettgau
Ivano-Frankivsk
Straubing
Linz
Memmingen
Knonau
Shanghai
Asten
Budapest
Singapur
Sibiu
Bilbao
Barcelona
Madrid
Dubai
GERMANY
SPAIN
SWITZERLAND
UAE
CHINA
MEMMINGEN
TEL +49-8331-937233
FAX +49-8331-937380
MADRID
TEL +34-91-659-3185
FAX +34-91-659-3139
KNONAU
TEL +41-44-76855-55
FAX +41-44-76855-30
DUBAI
TEL +971-4-883-8445
FAX +971-4-883-8446
SHANGHAI
TEL +86-21-56778006
FAX +86-21-56779229
MÜLHEIM
TEL +49-208-429010
FAX +49-208-4290143
BARCELONA
TEL +34-93-589-8446
FAX +34-93-589-8446
RUSSIA
HUNGARY
USA
STRAUBING
TEL +49-9421-914098
FAX +49-9421-914099
BILBAO
TEL +34-94-405-6332
FAX +34-94-405-6654
MOSKAU
Tel. +7-495-363-01-27
Fax +7-495-363-01-28
BUDAPEST
TEL +36-1-2601014
FAX +36-1-2620927
HAMPTON
TEL +1-7578252544
FAX +1-7578252546
ST. PETERSBURG
Tel. +7-812-740-12-24
Fax +7-812-493-48-21
POLAND
GREAT BRITAIN
WROCŁAW
TEL +48-71-3980760
FAX +48-71-3980769
CREWE
TEL +44-1270-587728
FAX +44-1270-587913
AUSTRIA
ASTEN
TEL +43-7224-662240
FAX +43-7224-6622413
LUXEMBOURG
SCHIFFLANGE
TEL +352-574242
FAX +352-574262
SOUTHAMPTON
TEL +44-23-8066-5470
FAX +44-23-8066-5471
08.13.pdf WA 257065
Service-Centres in:
Berlin, Hamburg
and additional test service
centres in Mannheim and
Munich